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EWIKON HPS III Series Operating Manual

Hot runner systems for side gating
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Valid for:
HPS III adapter nozzles
HPS III-MHL100/200 nozzles
HPS III-MHR100/200 nozzles
HPS III-MHR111 nozzles
HPS III-MHR112 nozzles
HPS III-MHR122 nozzles
HPS III-MH1 nozzles
HPS III-T/TE manifolds
Complete hot halves
Version: 2.0
HPS III hot runner systems
for side gating
Operating manual

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Summary of Contents for EWIKON HPS III Series

  • Page 1 HPS III hot runner systems Valid for: for side gating HPS III adapter nozzles HPS III-MHL100/200 nozzles Operating manual HPS III-MHR100/200 nozzles HPS III-MHR111 nozzles HPS III-MHR112 nozzles HPS III-MHR122 nozzles HPS III-MH1 nozzles HPS III-T/TE manifolds Complete hot halves Version: 2.0...

  • Page 3: Table Of Contents

    Content General remarks ................................7 Information on this operating manual ..........................7 Manufacturer ................................. 7 Formal information on the operating manual ........................ 7 Conventions .................................. 8 1.4.1 Instructions and system responses ..........................8 1.4.2 Enumerations ................................8 1.4.3 Abbreviations ................................8 Safety instructions ..............................
  • Page 4 Content 5.1.4 Attachment points ............................... 22 5.1.5 Working load limit for lifting accessories and slings ....................22 5.1.6 Removal from transport crate ............................24 5.1.7 Transport and movement during installation ....................... 24 General safety instructions ............................26 Technical Requirements .............................. 29 5.3.1 Tools and operating materials .............................
  • Page 5 Content Possible malfunctions ............................... 108 6.4.1 Troubleshooting ................................. 108 Maintenance ................................109 Safety instructions ..............................109 Instructions for maintenance ............................. 109 Maintenance schedule .............................. 109 Deinstallation / installation of tip inserts for HPS III-MH nozzles ................110 7.4.1 Safety instructions ..............................110 7.4.2 Deinstallation / installation of tip inserts for HPS III-MH nozzles ................
  • Page 6 HPS-III-Seitenanspritzung-Heißkanalsystem_Inhalt_BA_V-2-0_EN...

  • Page 7: General Remarks

    1.3 Formal information on the operating manual Person in charge of documentation: Henning Becker Item number: not specified Version: Printing date: 21/04/2020 Language: German (original operating manual) © Copyright, 2020 All rights reserved. Full or partial reproduction subject to prior written approval by EWIKON Heißkanalsysteme GmbH HPS-III-Heißkanalsystem_Vorspann_BA_V-2-0_EN...

  • Page 8: Conventions

    General remarks 1.4 Conventions 1.4.1 Instructions and system responses Operating steps that have to be carried out by the operator are displayed as a numbered list. The sequence of the steps has to be adhered to. Example: 1. Operating step 1 2.

  • Page 9: Safety Instructions

    Safety instructions 2. Safety instructions The HPS III hot runner system conforms to the machinery directive 2006/42/EG and has been designed, manufactured and checked for safety according to the applicable safety rules and legislation and the state of the art. The HPS III hot runner system is delivered in perfect working order.

  • Page 10: Signal Words For Hazard Classification

    Safety instructions 2.1.1 Signal words for hazard classification HAZARD! indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING! indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. CAUTION! indicates a potentially hazardous situation which, if not avoided, will result in minor injury or material damage.

  • Page 11: Intended Use

    Any different and unintended use is excluded and may result in personal injuries and material damage. Warranty expires in this case. EWIKON hot runner systems and single nozzles are only to be used for injection moulding applications, assembled in an enclosed injection mould. They are used to process thermoplastic resins according to their individual processing requirements and to pass them gently from the injection unit to the cavity by optimum temperature distribution and flow paths.

  • Page 12: Personal Protective Equipment (Ppe)

    Safety instructions 2.5 Personal Protective Equipment (PPE) Wear the necessary protective equipment when working on or near the machine. Special information on the personal protective equipment in the work area has to be observed. 2.5.1 Symbols of the personal protective equipment Always wear the following when carrying out any work: Protective clothes: To protect your body wear tight-fitting clothes with low resistance to tearing, without protruding parts and with long sleeves and long trousers.
  • Page 13 Safety instructions Risk of burns • Hot surfaces Many components of the hot runner systems get very hot and may cause severe skin burns when being touched. • Hot material (plastic melt) Never touch material leaking from the nozzle/the mould/the hot runner or the material inlet. Even material that seems to be cooled down already may still be hot inside the core and cause burns.

  • Page 14: Electrical Equipment

    The use of non-OEM spare and wear parts as well as auxiliary material may pose risks. Only use original parts or parts approved by EWIKON Heißkanalsysteme GmbH. Only use auxiliary and operating materials which are suitable for their intended use (compare chapter „5.3 Technical Requirements“).

  • Page 15: Warranty Terms

    2.10 Warranty terms For warranty conditions of cold and hot runner systems and components please refer to the terms and conditions of EWIKON. 2.11 Standards and directives EWIKON hot runner systems conform to the following European directives: • Machinery Directive 2006/42/EC •...

  • Page 16: Technical Data

    Technical data 3. Technical data 3.1 Mechanical specifications 3.1.1 Main dimensions of the HPS III hot runner system Description Quantity/size (approx.) Unit Dimensions See catalogue / PO-related documents mm Weight See catalogue / PO-related documents kg Chart 2: Main dimensions of the HPS III hot runner system 3.1.2 Operating parameters of the HPS III hot runner system Description Quantity/size (approx.)

  • Page 17: Cooling Agent

    Technical data 3.4.2 Cooling agent The use of unsuitable cooling agents may result in deposits and corrosion in the component to be cooled. This will negatively affect the functionality of the hot runner system. Components of the hot runner system may be damaged by a reduced coo- ling performance in the worst case. Cooling agents (water) have to satisfy the following minimum requirements: •...

  • Page 18: Functional Description Of The Hps Iii Hot Runner System

    Functional description of the HPS III hot runner system 4. Functional description of the HPS III hot runner system The schematic diagrams of the components of a HPS III hot runner system and the installation space shown in this docu- ment should not be regarded as the only valid general layout but only present one of many possible assembly configura- tions.
  • Page 19 Functional description of the HPS III hot runner system Start of cycle Valve gate nozzle(s) open(s)* Valve gate nozzle(s) close(s)* Picture 3: Injection moulding cycle * for valve gate systems ** recommended for open systems A hot runner system is used to distribute plastic melt between the injection moulding unit of an injection moulding machine and the cavities of an injection mould (compare picture 2).

  • Page 20: Installation

    Installation 5. Installation The following information is intended to help you install the HPS III hot runner system. In addtion, the assembly staff has to have the know-how required to install an HPS III hot runner system. The described installation processes are examples for standard nozzles and standard systems. Special systems may require different procedures! Please observe the instructions in the order specific documents. 5.1 Transport This chapter describes how to transport a hot runner system without damaging it and how to ensure occupational safety for the staff.

  • Page 21: Recommended Lifting Accessories And Slings

    • • Spacer bolt for attachment swivel (allowed for L2X systems only, can only be purchased from EWIKON). The spacer bolts must not be used for other transport processes! See PPicture 6. They should only be used when attach- ment swivels can not be used for lack of space.

  • Page 22: Attachment Points

    Before transport the working load limit for the used lifting accessories and slings must be checked in the following order: 1. How heavy is the load? • The weight of single components, systems or hot halves is indicated on the EWIKON note of delivery (net weight, without packaging). If this information is not available anymore the weight can be estimated. However, there should be a sufficient margin up •...
  • Page 23 Installation 3. Is one single attachment point sufficient to lift the load vertically stretched or is more than one attachment point necessary to lift the load? Only for the transport of hot halves, nozzle sides or individual mould plates usually one single attachment point is suffici- • ent (see Picture 13) as the gravity centre usually coincides with the attachment point! In this case the lifting capacity is 100 %.

  • Page 24: Removal From Transport Crate

    Depending on the manufacturer and design of the attachment swivel the maximum possible load capacity must no longer be utilized. If the attachment swivels recommended by EWIKON are used for such installation work (see chapter „5.1.2 Recommended lifting accessories and slings“), the maximum load capacity of an attachment swivel should always be reduced by at least the half.
  • Page 25 Installation Putting hot runner assemblies (hot halves, mould plates, manifolds or L2X systems) from lying (horizontal) into upright (vertical) position. 1. The hot runner assembly must be placed on an even, 100% load capacity non-slip surface. 2. Screw in attachment swivels and affix them to a crane. 3. Put a wooden lath on the working surface and secure against slipping.

  • Page 26: General Safety Instructions

    Installation NOTE! Pay attention to system characteristics The work steps described just show how to move the system most commonly. Depending on the system layout further measures which have to be determined individually may be necessary to move and assemble hot runner assemblies in a safe way.
  • Page 27 Dimensional check (for details please also see chapter „5.4 Checks before installation“) Check of the given installation dimensions, fit sizes, form and location tolerances of the mould plates surround- ing the hot runner system (for information please see the current catalogues in the download section on www. ewikon.com). The following dimensions have to be checked in particular: • Mould plate dimensions.
  • Page 28 Installation Protect the cable ends When wiring the system make sure that the thermo and power lines do not protrude from the outer edges of the mould and are protected against damage. The distances between hot runner and cables inside the mould have to be dimensioned in such a way that there is no damage to the components caused by excessive heat.

  • Page 29: Technical Requirements

    Installation 5.3 Technical Requirements Specific connections and hoses are used for supply lines (hydraulic, cooling water). 5.3.1 Tools and operating materials Tool Version EWIKON item no. Abrasive paper / Exchange of nozzle heater Various non-woven web Allen key For hexagon socket head cap screw Depending on system and components. according to DIN EN ISO 4062 For wrench sizes see chapter „9.
  • Page 30 Installation Tool Version EWIKON item no. Cleaning of flow channels Maintenance mouthpiece ask EWIKON Mandrel Installation of cable marker Metal cable tie Fixation of cables of L2X systems 19667 Multimeter Measuring of resistance Outside micrometre Control of check dimensions Oxy-acetylene burner Deinstallation of a screw bush...
  • Page 31 Installation Tool Version EWIKON item no. For specifications see manufacturer Webbing slings and round Lifting and moving of hot halves, slings systems (L2X) and plate assemblies Wire brush, soft Cleaning of e.g sealing surfaces Preferably brass wire, do not use brass- coated wire or steel wire...

  • Page 32: Standard Parts

    Only standard parts which are approved for operation in EWIKON hot runner systems must be used. The following standard parts with the associated standards are approved for EWIKON hot runner systems. Particularly for screws the associated strength classes (see chapter 5.5 Assembly of the system / the components) and tightening torques (compare chapter „9.

  • Page 33: Checks Before Installation

    Check of gate diameter NOTE! See the EWIKON HPS III catalogue, chapter 5 "General assembly notes" , for a detailled description of general assembly notes and mould layout. The current version of the catalogue can be found on www.ewikon.com in the download section.

  • Page 34: Dimensions To Be Checked For A Hot Runner System With Hps Iii-Mhl And Hps Iii-Mhr Nozzles

    Installation 5.4.3 Dimensions to be checked for a hot runner system with HPS III-MHL and HPS III-MHR nozzles z349-02 Picture 22: Example: Dimensions to be checked for a hot runner system with HPS III-MHL (left) and HPS III-MHR (right) nozzles HPS-III-Heißkanalsystem_Vorspann-Prüfmaße-MH_BA_V-2-0_EN...
  • Page 35 Pressure pad with centering Delta S M : Gap between pressure pad with centering and base of the corresponding recess. Pos. 6 Lock against rotation of manifold Installation space (for EWIKON parts) Pos. 7 Tilting preventing pad of manifold Manifold height Pos. 8...
  • Page 36 HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...

  • Page 37: Installation Of Hps Iii Adapter Systems

    Pos. 54 Intermediate plate Use approved standard parts only Only standard parts which are approved for use in EWIKON hot runner systems must be used. See chapter „5.3 Technical Requi- rements“. Screw connection for manifold The screw connection for the manifold (pos.
  • Page 38 Installation of HPS III adapter systems Installation of an adapter nozzle for standard installation HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 39 Installation of HPS III adapter systems Installation of an adapter nozzle for front installation HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 40 (pos. 53) and the contact surface for the centre support of the manifold and compare it to the value given in the drawing provided by EWIKON. z346-04 Picture 26: Check of reference dimensions before installation of...
  • Page 41 Installation of HPS III adapter systems Manifold installation - installation procedure HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 42 (pos. 1.4) and the surface of the nozzle retainer frame plate (pos. 53) and compare it to the value given in the drawing provided by EWIKON. 2. Install the clamping plate (pos. 51) and the insulating plate (pos. 50).

  • Page 43: Installation Of Hps Iii Hot Runner Systems For Direct Side Gating

    „5.4 Checks before installation“ must be checked and compared with the values provided with the installation drawing. Use approved standard parts only Only standard parts which are approved for use in EWIKON hot runner systems must be used. See chapter „5.3 Technical Requi- rements“.
  • Page 44 Installation of HPS III hot runner systems for direct side gating HHPS III-MHL 100/200 nozzle - installation of nozzle body HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 45 Installation of HPS III hot runner systems for direct side gating HPS III-MHL100/200 nozzle - installation of tip inserts WARNING! Hot surfaces Burns to the body caused by hot surfaces. 1. Install tip inserts (pos. 2.2). Ensure that they are positi- oned correctly and that the sealing surfaces between tip insert and nozzle are clean.
  • Page 46 Installation of HPS III hot runner systems for direct side gating HPS III-MHR100/200 nozzle - installation of nozzle body HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 47 Installation of HPS III hot runner systems for direct side gating HPS III-MHR100/200 nozzle - installation of tip inserts WARNING! Hot surfaces Burns to the body caused by hot surfaces. 1. Install tip inserts (pos. 3.2). Ensure that they are positi- oned correctly and that the sealing surfaces between tip insert and nozzle are clean.
  • Page 48 (pos. 52) and compare it to the value given in the z346-12 drawing provided by EWIKON. The drawing also contains Picture 36: Check of reference dimensions before installation of the dimension H3 of the manifold.
  • Page 49 Installation of HPS III hot runner systems for direct side gating Manifold installation - installation procedure HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 50 Installation of HPS III hot runner systems for direct side gating Manifold installation - installation of clamping plate and locating ring HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. •...
  • Page 51 T between the contact surface of the nozzle adapter and the upper surface of the nozzle retainer plate. The clearance ∆S ∆S Tolerance: ± 0,01 mm; ± 0,02 mm for dimension G of nozzle ≥ 200 mm Compare the calculated clearance to the value given in the drawing provided by EWIKON. HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...
  • Page 52 Installation of HPS III hot runner systems for direct side gating Final installation of the system HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.

  • Page 53: Installation Of Systems With Hps Iii-Mhr111 Nozzles

    „5.4 Checks before installation“ must be checked and compared with the values provided with the installation drawing. Use approved standard parts only Only standard parts which are approved for use in EWIKON hot runner systems must be used. See chapter „5.3 Technical Requi- rements“.
  • Page 54 Installation of HPS III hot runner systems for direct side gating HPS III-MHR111 nozzle - installation of nozzle body HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 55 Installation of HPS III hot runner systems for direct side gating HPS III-MHR111 nozzle - installation of tip inserts WARNING! Hot surfaces Burns to the body caused by hot surfaces. 1. Install tip inserts (pos. 2.2). Ensure that they are positi- oned correctly and that the sealing surfaces between tip insert and nozzle are clean.
  • Page 56 (pos. 55) to the contact surface (sealing surface) in the MH nozzle. The clearance ∆S ∆S Compare the calculated clearance to the value given in the drawing provided by EWIKON. HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...
  • Page 57 Installation of HPS III hot runner systems for direct side gating HPS III-MHR111 nozzle - final installation of plate assemblies HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 58 Installation of HPS III hot runner systems for direct side gating HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...

  • Page 59: Installation Of Systems With Hps Iii-Mhr112 Nozzles

    „5.4 Checks before installation“ must be checked and compared with the values provided with the installation drawing. Use approved standard parts only Only standard parts which are approved for use in EWIKON hot runner systems must be used. See chapter „5.3 Technical Requi- rements“.
  • Page 60 Installation of HPS III hot runner systems for direct side gating HPS III-MHR112 nozzle - installation of nozzle body HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 61 Installation of HPS III hot runner systems for direct side gating HPS III-MHR112 nozzle - installation of tip inserts WARNING! Hot surfaces Burns to the body caused by hot surfaces. 1. Install tip inserts (pos. 2.2). Ensure that they are positi- oned correctly and that the sealing surfaces between tip insert and nozzle are clean.
  • Page 62 (pos. 55) to the contact surface (sealing surface) in the MH nozzle. The clearance ∆S ∆S Compare the calculated clearance to the value given in the drawing provided by EWIKON. HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...
  • Page 63 Installation of HPS III hot runner systems for direct side gating HPS III-MHR112 nozzle - final installation of plate assemblies HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 64 Installation of HPS III hot runner systems for direct side gating HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...

  • Page 65: Installation Of Systems With Hps Iii-Mhr122 Nozzles

    „5.4 Checks before installation“ must be checked and compared with the values provided with the installation drawing. Use approved standard parts only Only standard parts which are approved for use in EWIKON hot runner systems must be used. See chapter „5.3 Technical Requi- rements“.
  • Page 66 Installation of HPS III hot runner systems for direct side gating HPS III-MHR122 nozzle - installation of nozzle body HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 67 Installation of HPS III hot runner systems for direct side gating HPS III-MHR122 nozzle - installation of tip inserts WARNING! Hot surfaces Burns to the body caused by hot surfaces. 1. Install tip inserts (pos. 2.2). Ensure that they are positio- ned correctly and that the sealing surfaces between tip insert and nozzle are clean.
  • Page 68 (pos. 53) and the contact surface for the centre support of the manifold and compare it to the value given in the drawing provided by EWIKON. z346-30 Picture 55: Check of reference dimensions before installation of...
  • Page 69 Installation of HPS III hot runner systems for direct side gating Manifold installation - installation procedure HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 70 (pos. 1.4) and the surface of the nozzle retainer frame plate (pos. 53) and compare it to the value given in the drawing provided by EWIKON. 2. Install the clamping plate (pos. 51) and the insulating plate (pos. 50).

  • Page 71: Installation Of Systems With Hps Iii-Mh1 Nozzles For Side Gating With Open Flow Channel

    „5.4 Checks before installation“ must be checked and compared with Pos. 56 Contour plate (fixed mould half) the values provided with the installation drawing. Use approved standard parts only Only standard parts which are approved for use in EWIKON hot runner systems must be used. See chapter „5.3 Technical Requi- rements“. Screw connection for manifold The screw connection for the manifold (pos.
  • Page 72 Installation of HPS III hot runner systems for direct side gating Installation of a HPS III-MH1 nozzle for standard installation HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 73 Installation of HPS III hot runner systems for direct side gating Installation of a HPS III-MH1 nozzle for front installation HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 74 (pos. 53) and the contact surface for the centre support of the manifold and compare it to the value given in the drawing provided by EWIKON. z346-36 Picture 63: Check of reference dimensions before installation of...
  • Page 75 Installation of HPS III hot runner systems for direct side gating Manifold installation - installation procedure HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- nents. • The hot runner system and the mould have to be disconnected from the voltage source during installation.
  • Page 76 (pos. 1.4) and the surface of the nozzle retainer frame plate (pos. 53) and compare it to the value given in the drawing provided by EWIKON. 2. Install the clamping plate (pos. 51) and the insulating plate (pos. 50).
  • Page 77 Installation of HPS III hot runner systems for direct side gating HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...

  • Page 78: Installation Of A Hot Half With Hps Iii-Mh Nozzles

    „5.4 Checks before installation“ must be checked and compared with the values provided with the installation drawing. Use approved standard parts only Only standard parts which are approved for use in EWIKON hot runner systems must be used. See chapter „5.3 Technical Requi- rements“.
  • Page 79 Introduction and preliminary measures z351-08 Picture 68: Preliminary measures 1. Lift the hot half carefully out of the transport crate. Due to the better force application point EWIKON re- WARNING! commends to use attachment swivels only (pos. a, see Suspended load chapter „5.1 Transport“...
  • Page 80 Installation of HPS III hot runner systems for direct side gating Installation - hot half with HPS III-MHL 100/200 or HPS III-MHR 100/200 nozzles z351-06 Picture 69: Installation HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...
  • Page 81 Connected power supply during installation installation drawing provided by EWIKON. For required reference dimensions also see chapters „5.4 Checks Risk of deadly electric shock or severe injuries due to live compo- nents.
  • Page 82 Installation of HPS III hot runner systems for direct side gating Installation - hot half with HPS III-MHR111 or HPS III-MHR112 nozzles z351-07 Picture 70: Installation HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...
  • Page 83 Connected power supply during installation installation drawing provided by EWIKON. For required reference dimensions also see chapters „5.4 Checks be- Risk of deadly electric shock or severe injuries due to live compo- nents.
  • Page 84 Installation of HPS III hot runner systems for direct side gating Installation - hot half with HPS III-MHR122 nozzles z351-05 Picture 71: Installation HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...
  • Page 85 Connected power supply during installation installation drawing provided by EWIKON. For required reference dimensions also see chapter Risk of deadly electric shock or severe injuries due to live compo- nents.
  • Page 86 Installation of HPS III hot runner systems for direct side gating Installation - hot half with HPS III-MH1 nozzles z351-04 Picture 72: Installation HPS-III-Seitenanspritzung-Heißkanalsystem_Montage_BA_V-2-0_EN...
  • Page 87 Connected power supply during installation installation drawing provided by EWIKON. For required reference dimensions also see chapter Risk of deadly electric shock or severe injuries due to live compo- nents.

  • Page 88: Electrical Connection Of Hot Runner Systems

    Electrical connection of hot runner systems 5.7 Electrical connection of hot runner systems 5.7.1 Safety instructions HAZARD! Connected power supply during installation Risk of deadly electric shock or severe injuries due to live components. • The HPS III hot runner system, the single tip, the hot half and the mould have to be disconnected from the voltage source during installation.
  • Page 89 Electrical connection of hot runner systems NOTE! Mechanical stress of cable ends The cable ends must not be subject to tensile stress. Protect the cable ends When wiring the system make sure that the thermo and power lines do not protrude from the outer edges of the mould and are protected against damage.

  • Page 90: General Information

    Electrical connection of hot runner systems 5.7.2 General information Wiring of the hot runner components must be performed by qualified staff according to DIN EN 60204-1 and the generally recognized codes of practice. Heaters designed for a rated voltage of 230V AC are used. Please make sure that the voltage applied corresponds to this specification. The heaters are connected to the plug according to the arrangement given in the wiring diagram of the respec- tive hot runner system. The following pictures give an overview of the cable assignment of HPS III nozzles and manifolds. 230V L (orange) N (grey)
  • Page 91 Electrical connection of hot runner systems Thermo + (black) Side view of manifold - (white) L (brown) 230V N (blue) 230V Thermo Top view of manifold Top view of manifold z343-03 Picture 74: Cable assignment of HPS III manifolds (shown: one control zone) L (black) 230V N (blue)
  • Page 92 The power and thermo collective plugs are numbered consecutively: (230 V: X-1.1, X-2.1, X-3.1... / Thermo: X-1.2, X-2.2, X-3.2..). EWIKON recommends to apply this numbering scheme also when purchasing components instead of hot halves. A - A view on tips X-2.1...
  • Page 93 Electrical connection of hot runner systems Wiring order (Example: 6-drop system): The control zones are numbered consecutively, beginning at the position of the first nozzle (top left). Each control zone has a heater and a thermocouple assigned. First all nozzles (H-01 - H-06) should be wired, then all manifold heaters (M-01 - M-02) and at last the heater of the connecting nozzle (CN-01). The contact allocation follows DIN 16765, part A. Detailed wiring instructions for standard system configurations are shown on the following pages.

  • Page 94: Wiring Of 1-Drop Hot Runner Systems

    Electrical connection of hot runner systems 5.7.3 Wiring of 1-drop hot runner systems Picture 78: Wiring of standard-1-drop hot runner systems X-1.1 X-1.2 Key to the symbols Control zone Heater nozzle Heater manifold 230 V Thermo Control Plug 230 V / 10-pin Contact Plug thermo / 10-pin Contact...

  • Page 95: Wiring Of 2-Drop Hot Runner Systems

    Electrical connection of hot runner systems 5.7.4 Wiring of 2-drop hot runner systems Picture 79: Wiring of standard-2-drop hot runner systems X-1.1 X-1.2 Key to the symbols Control zone Heater nozzle Heater manifold 230 V Thermo Control Plug 230 V / 10-pin Contact Plug thermo / 10-pin Contact...

  • Page 96: Wiring Of 4-Drop Hot Runner Systems (Manifold With 2 Control Zones)

    Electrical connection of hot runner systems 5.7.5 Wiring of 4-drop hot runner systems (manifold with 2 control zones) Picture 80: Wiring of standard-4-drop hot runner systems (manifold with two control zones) X-1.1 X-1.2 Key to the symbols Control zone Heater nozzle Heater manifold 230 V Thermo...

  • Page 97: Wiring Of 6-Drop Hot Runner Systems (Manifold With 2 Control Zones)

    Electrical connection of hot runner systems 5.7.6 Wiring of 6-drop hot runner systems (manifold with 2 control zones) Picture 81: Wiring of standard-6-drop hot runner systems (manifold with two control zones) X-1.2 Key to the symbols X-1.1 Control zone Heater nozzle Heater manifold Heater band sprue bush...

  • Page 98: Wiring Of 8-Drop Hot Runner Systems (Manifold With 2 Control Zones)

    Electrical connection of hot runner systems 5.7.7 Wiring of 8-drop hot runner systems (manifold with 2 control zones) Picture 82: Wiring of standard-8-drop hot runner systems (manifold with two control zones) X-1.2 Key to the symbols X-1.1 Control zone Heater nozzle Heater manifold Heater band sprue bush...

  • Page 99: Wiring Of 8-Drop Hot Runner Systems (Manifold With 4 Control Zones)

    Electrical connection of hot runner systems 5.7.8 Wiring of 8-drop hot runner systems (manifold with 4 control zones) Picture 83: Wiring of standard-8-drop hot runner systems (manifold with four control zones) X-2.1 X-2.2 X-1.1 X-1.2 230 V Thermo Key to the symbols Control Plug 230 V / 24-pin Contact...

  • Page 100: Checks After Installation

    (for a short time) • Check response of the respective thermocouple • When using a EWIKON controller this procedure can be automatically carried out by using the diagnosis function. To be checked in heated condition (operating temperature) Leak tightness and function of drive units (hydraulic fluid, pressurised air) by repeatedly moving the valve pin to the end • positions in manual mode while the mould is opened.

  • Page 101: Start-Up And Instructions For Operation

    Injection moulding processes must only be carried out with maximum pressures of 2000 bar. If the process requires higher pressures a written permission of EWIKON Heißkanalsysteme GmbH is needed.
  • Page 102 Start-up and instructions for operation CAUTION! A HPS III hot runner system must only be started up when used as intended within an injection mould. Respect operating temperatures For all further checks the HPS III hot runner system must be heated to operating tem- perature in order to avoid damage to hot runner components.

  • Page 103: Requirements For Operation

    Start-up and instructions for operation 6.2 Requirements for operation • The radius of the sprue bush (R) or the radius of the contact surface of a single tip respectively has to be adapted to the radius of the machine nozzle (R M ) (recommendation: R > R M + 1). •...

  • Page 104: Start-Up And Operation Of Hot Runner Systems With Hps Iii-Mh Nozzles

    Start-up and operation of hot runner systems with HPS III-MH nozzles 6.3 Start-up and operation of hot runner systems with HPS III-MH nozzles 6.3.1 First-time start-up and filling of a hot runner system with HPS III-MH nozzles with heat conductive tips •...

  • Page 105: First-Time Start-Up And Filling Of A Hot Runner System With Hps Iii-Mh Valve Gate Nozzles

    In order to reduce the load on the valve pin during operation to a minimum the pressure for hydraulic drives hould not exceed 50 bar. For normal operation EWIKON recommends approx. 30 bar. For valve gate systems with pneumatic drives compressed air with a pressure of 6 - 8 bar should be provided (dry, dehumidified air).

  • Page 106: Start-Up Of Already Filled Hot Runner Systems With Hps Iii-Mh Valve Gate Nozzles

    In order to reduce the load on the valve pin during operation to a minimum the pressure for hydraulic drives hould not exceed 50 bar. For normal operation EWIKON recommends approx. 30 bar. For valve gate systems with pneumatic drives compressed air with a pressure of 6 - 8 bar should be provided (dry, dehumidified air).

  • Page 107: Shutdown Of A System With Hps Iii-Mh Nozzles (System / Single Tip / Single Cavity)

    Start-up and operation of hot runner systems with HPS III-MH nozzles 6.3.6 Shutdown of a system with HPS III-MH nozzles (system / single tip / single cavity) CAUTION! Damage of system • In case of heater failure of the nozzle adapter or the nozzle body stop moulding immediately! There is the risk of leakage due to missing thermal expansion in length of the nozzle.

  • Page 108: Possible Malfunctions

    Possible malfunctions 6.4 Possible malfunctions 6.4.1 Troubleshooting Error Possible cause / measure Temperature of control zone exceeds Check if the thermocouple and power connections are allocated correctly set temperature (heat up each zone separately). Controller indicates broken thermocoup- Check thermocouple at the nozzle and/or thermocouple cable and controller le.

  • Page 109: Maintenance

    Maintenance 7. Maintenance 7.1 Safety instructions WARNING! Hot surfaces / hot material (plastic melt) Body burns by hot surfaces. • Let the HPS III hot runner system and all components cool down completely to ambient temperature before starting maintenance work / disassembling. Never touch material leaking from the nozzle/the mould/the hot runner or the material inlet.

  • Page 110: Deinstallation / Installation Of Tip Inserts For Hps Iii-Mh Nozzles

    If a nozzle tip can not be screwed out use the controller to raise the nozzle temperature in steps. • If the nozzle tip is still not screwable please contact the EWIKON customer servide. See chapter „7.7 Inst- ructions for service and repair“.

  • Page 111: Deinstallation / Installation Of Tip Inserts For Hps Iii-Mh Nozzles

    Maintenance 7.4.2 Deinstallation / installation of tip inserts for HPS III-MH nozzles z289-02 z289-01 Picture 84: HPS III-MHL 100/200 nozzle Picture 85: HPS III-MHR 100/200 nozzle Pos. 2.2 Tip insert Pos. 3.2 Tip insert Pos. 2.3 Clamping cover Pos. 3.3 Clamping cover Pos.

  • Page 112: Deinstallation Of Tip Inserts

    Maintenance 7.4.3 Deinstallation of tip inserts WARNING! Sharp edges and heavy components • Cut injuries to body and extremities, mainly to the hands. Unscrew and Crushing of fingers or hand. • remove clamping Hot surfaces cover Burns to the body caused by hot surfaces. 1.

  • Page 113: Hps Iii-Mhl100/200 (Valve Gate) Nozzles - Exchange Of Thermocouple

    Maintenance 7.5 HPS III-MHL100/200 (valve gate) nozzles – exchange of thermocouple Adapter zone Nozzle zone Picture 87: HPS III-MHL100 nozzle Pos. 2a Protective tube of adapter HAZARD! Pos. 3 Thermocouple of nozzle Pos. 3a Thermocouple of adapter Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- Pos.
  • Page 114 Maintenance HPS III-MHL100/200 (valve gate) nozzles – exchange of thermocouple Exchange of thermocouple in the adapter zone (HPS III-MHL nozzle) 1. Clamp the nozzle body in a vice. Unscrew and remove the adapter by using a ring spanner insert. Picture 88: Clamp the nozzle and unscrew the adapter Picture 89: Disassembled adapter 2.
  • Page 115 Maintenance HPS III-MHL100/200 (valve gate) nozzles – exchange of thermocouple Picture 92: Clamp the protective tube pull out the heating element 4. The adapter heater and the thermocouple are connec- ted by a protective hose and cable ties. Disconnect the thermocouple, disassemble the broken thermocouple from the cutout and pull it out of the bore in the heating element.
  • Page 116 Maintenance HPS III-MHL100/200 (valve gate) nozzles – exchange of thermocouple Exchange of thermocouple in the nozzle zone (HPS III-MHL nozzle) 1. Clamp the nozzle body at the side bars in a vice. Picture 96: Clamp the nozzle, unscrew socket head screw 2.

  • Page 117: Hps Iii-Mhr100/200 (Valve Gate) Nozzles - Exchange Of Thermocouple

    Maintenance 7.6 HPS III-MHR100/200 (valve gate) nozzles – exchange of thermocouple Adapter zone Nozzle zone Picture 100: HPS III-MHL100 nozzle Pos. 2 Protective tube of nozzle HAZARD! Pos. 2a Protective tube of adapter Pos. 3 Thermocouple of nozzle Connected power supply during installation Risk of deadly electric shock or severe injuries due to live compo- Pos.
  • Page 118 Maintenance HPS III-MHR100/200 (valve gate) nozzles – exchange of thermocouple NOTE! For the thermocouple exchange a clamping device is available to secure the HPS III-MHR nozzle against rotation! Using this device is not absolutely necessary but enhances the maintenance work. See chapter „5.3.1 Tools and operating materials“.
  • Page 119 Maintenance HPS III-MHR100/200 (valve gate) nozzles – exchange of thermocouple 3. For disassembly of the protective tube from the heating element of the adapter coat the all parts with WD 40 pe- netrating oil and let it soak for a while. Pull the protective tube off. (Tipp: It may be necessary to use two screwdri- vers as levers to untighten the protective tube.) 4.
  • Page 120 Maintenance HPS III-MHR100/200 (valve gate) nozzles – exchange of thermocouple NOTE! For the thermocouple exchange a clamping device is available to secure the HPS III-MHR nozzle against rotation! Using this device is not absolutely necessary but enhances the maintenance work. See chapter „5.3.1 Tools and operating materials“.
  • Page 121 Maintenance HPS III-MHR100/200 (valve gate) nozzles – exchange of thermocouple 5. Clamp the nozzle carefully and slightly at the nozzle body. 6. Bend the nozzle heater carefully into an upright position. Coat the protective tube with WD 40 penetrating oil. 7.

  • Page 122: Instructions For Service And Repair

    In case of service requests please always have the serial number, order number and type of the used hot runner system ready. • Service www.ewikon.com in the "Contact" menue, submenue "Sales network", "Your contact at EWIKON", "Service department" E-Mail: service@ewikon.com HPS-III-Heißkanalsystem_Servicehinweise_Außerbetriebnahme_BA_V-2-0_EN...

  • Page 123: Decommissioning

    Decommissioning 8. Decommissioning 8.1 Safety instructions HAZARD! Connected power supply during deinstallation Risk of deadly electric shock or severe injuries due to live components. • The hot runner components and the mould have to be disconnected from the voltage source during deins- tallation.

  • Page 124: Instructions For Disposal

    Once disposed components must not be used again. EWIKON disclaims any responsibility for personal injuries and material demage resulting from re-use. In case that no special arrangements regarding return or disposal were agreed with EWIKON the disassembled components have to be recycled after deinstallation: •...

  • Page 125: Tightening Torques

    The values are to be understood as maximum permissible tightening torques (without safety factor). • Only calibrated tightening tools must be used. (When the tightening method/ the tightening tool shows a greater variation (approx. > ±5%) the required tightening torque M A must be appropriately reduced to avoid overstressing (control test required). It must be considered that different tigh- tening methods can show a different variation.) • EWIKON generally recommends to use screws with property class 12.9 only. HPS-III-Heißkanalsystem_Anziehdrehmomente-Zylinderschrauben-Verteilerverschraubung-Halteschrauben_BA_V-2-0_EN...
  • Page 126 Tightening torques Tightening torques for socket head screws Maximum permissible tightening torque M A at room temperature Lubricated (High temperature Screws in as-delivered condition installation paste, see chapter (slightly oiled) µ G =0.14 „5.3.1 Tools and operating mate- rials“) µ G =0.10 M A [Nm] M A [ft·lb] M A [Nm]...

  • Page 127: Tightening Torques For Manifold Screw Connections And Retaining Screws

    Tightening torques 9.2 Tightening torques for manifold screw connections and retaining screws Thread Tightening torque Lubricated (high temperature installation paste, see chapter „5.3.1 Tools and operating materials“) M A [Nm] M A [ft·lb] Chart 14: Tightening torques for manifold screw connections (for standard installation of nozzles) and retaining screws HPS-III-Heißkanalsystem_Anziehdrehmomente-Zylinderschrauben-Verteilerverschraubung-Halteschrauben_BA_V-2-0_EN...

  • Page 128: Tightening Torques For Clamping Covers Of Hps Iii-Mh Nozzles

    Tightening torques 9.3 Tightening torques for clamping covers of HPS III-MH nozzles HPS III-MHL 100/200 - versions and tightening torques Tightening torque Nozzle Width B [mm] No. of tips No. of screws M A [Nm] M A [ft·lb] MHL100 MHL200 11.8 Chart 15: Tightening torques for clamping covers of HPS III-MHL 100/200 nozzles HPS III-MHR 100/111/200 - versions and tightening torques...
  • Page 129 HPS-III-Heißkanalsystem_Rückseite_BA_V-2-0_EN...
  • Page 130 EWIKON Heißkanalsysteme GmbH Siegener Straße 35 35066 Frankenberg Tel: +49 6451 / 501-0 Fax: +49 6451 / 501-202 E-Mail: info@ewikon.com www.ewikon.com...

This manual is also suitable for:

Hps iii-mhl100Hps iii-mhl200Hps iii-mhr100Hps iii-mhr200Hps iii-mhr111Hps iii-mhr112 ... Show all

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